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大径厚比薄壁铝管1D弯曲半径成形方法
英文标题:One times relative bending radius forming method of thinwall aluminum tube with large ratio of diameter to thickness
作者:杨坪川 吴孔炜 李鑫 徐雪峰 熊光利 
单位:(1.航空工业成都飞机工业(集团)有限责任公司 四川 成都610092 2.南昌航空大学 航空制造工程学院  江西 南昌 330063   3.航空工业江西洪都航空工业集团有限责任公司 江西 南昌 330024) 
关键词:大径厚比 1D弯曲成形 内胀冷推弯 反推模拟 球形芯轴进给量 
分类号:TG376
出版年,卷(期):页码:2019,44(2):55-60
摘要:

 为解决大径厚比薄壁铝管在1D极难弯曲成形的技术瓶颈,对比现有液压填充、钢珠、松香及低熔点合金填充推弯成形技术优劣,提出一种采用聚氨酯弹性填料分块填充进行内胀冷推弯的成形方法。首先利用有限元反推模拟技术得到优化的1D弯曲半径弯头下料尺寸;其次利用优化下料尺寸对规格为Φ50 mm×1 mm的LF2M大径厚比薄壁铝管进行1D弯曲半径内胀冷推弯成形试验,主要研究了球形芯轴进给量对成形的影响。结果表明:通过反推模拟技术获得优化管坯下料尺寸方法具有可行性;球形芯轴的进给量是内胀冷推成形工艺的关键, 增大进给量能提高径向压应力,消除失稳起皱及减小截面畸变程度,而径向压应力过大则易造成成形不足;球形芯轴进给量为75°时,整体成形效果较好,外侧最大壁厚减薄率为6%,最大截面畸变率为2.3%,成功实现大径厚比薄壁管的1D弯曲成形。

 

 In order to solve the technical bottleneck of 1D extremely difficult bending of thinwalled aluminum tubes with large ratio of diameter to thickness, a new innerbulging and cold push bending method using polyurethanee elastic filler in block filling was proposed by comparing the advantages and disadvantages of pushbending filled with hydraulic filling, steel ball, rosin and low melting point alloy. Firstly, the optimized blanking size of 1D bending radius elbow was obtained by finite element backstepping simulation technology. Secondly, based on the optimized blanking size for Φ50 mm×1 mm in thinwalled aluminum tube with the large ratio of diameter to thickness, the innerbulging and cold push bending experiment of 1D bending radius forming was conducted, and the influence of the spherical mandrel feeding on the forming process was studied. The results show that it is feasible to optimize the blanking size by backstepping simulation technology, and the spherical mandrel feeding is the key to the innerbulging and cold push bending process. Furthermore, increasing feeding can increase the radial compressive stress, eliminate wrinkling and reduce the distortion of crosssection, while the excessive radial compressive stress can easily lead to insufficient forming. When the spherical mandrel feeding is 75°, the overall forming effect is better, the maximum wall thickness thinning rate is 6%, and the maximum crosssection distortion rate is 2.3%. Thus, the 1D bending of thinwalled tube with large ratio of diameter to thickness is successfully realized.

基金项目:
基金项目:国家自然科学基金资助项目(51405219); 江西省重点研发计划项目(20165ABC28002)
作者简介:
作者简介:杨坪川(1985-),男,学士,高级工程师 Email:285311180@qq.com 作者简介:徐雪峰 (1983-),男,博士,副教授 Email:xfwinzy@163.com
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